Composite Seat Cushion

ABSTRACT

A composite seat cushion includes a high-resiliency inner foam core, at least one gel-infused memory foam layer extending over at least a portion of a top surface of the inner foam core, and a first down proof tick layer positioned on top of the gel-infused memory foam layer.

CROSS-REFERENCE

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/002,532, filed May 23, 2014 (pending) thedisclosure of which is expressly incorporated by reference herein in itsentirety.

TECHNICAL FIELD

The present invention relates to a seat cushion and, more particularly,to composite seat cushion for providing increased comfort to an articleof furniture.

BACKGROUND

Seat cushions are known for use with chairs, couches, benches, and otherarticles of furniture to provide increased comfort to persons sitting onsuch furniture.

Seat cushions require a certain balance between softness and stiffnessin order to maximize comfort. Seat cushions that are overly soft mayfail to provide support to a person, while seat cushions that are overlystiff may be uncomfortable. High-comfort seat cushions that exhibit aproper balance of softness and stiffness are generally expensive tomanufacture, and thus may be costly to consumers. On the other hand,cheaply-made seat cushions frequently exhibit poor durability and weardown after repeated use. Therefore, a need exists for an inexpensive anddurable seat cushion that provides a high level of comfort.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a composite seat cushion in accordancewith the principles of the present invention.

FIG. 2 is a cutaway view of the composite seat cushion of FIG. 1.

DETAILED DESCRIPTION

Referring now to FIGS. 1 and 2, an exemplary composite seat cushion 10in accordance with the principles of the present invention is shown. Theseat cushion 10 may include a high-resiliency inner foam core 12 havinga top surface, a bottom surface (not shown), and four side surfaces. Inthis embodiment, the inner foam core 12 comprises a generallyrectangular shape. However, it will be appreciated that the inner foamcore 12 may comprise any other shape, such as square, circular,triangular, or any other shape suitable for a seat cushion 10. Thethickness (T) of the inner foam core 12 may be related to the size of acushion casing (not shown) that is intended to be encase inner foam core12. For example, the thickness (T) of the inner foam core 12 may besubstantially equal to a width dimension of a panel of the cushioncasing.

The seat cushion 10 may further include a first gel-infused memory foamlayer 14 positioned on the top surface of the inner foam core 12. In theembodiment shown, a second gel-infused memory foam layer 16 ispositioned on the bottom surface of the inner foam core 12. Thegel-infused memory foam layers 14, 16 may substantially cover the topand bottom surfaces, as shown, or may extend over any portions thereof.In other embodiments, the seat cushion 10 may not include a secondgel-infused memory foam layer 16. Moreover, it will be appreciated that,instead of using separate pieces of gel-infused memory foam material forthe first and second layers 14, 16, a single piece of gel-infused memoryfoam material may be wrapped around the inner foam core 12 to form thefirst and second layers 14, 16 over a portion of the top surface and aportion of the bottom surface of the inner foam core 12.

The gel-infused memory foam layers 14, 16 may comprise a viscofoammaterial, such as that sold by Hickory Springs Manufacturing Solutions,located in Hickory Springs, North Carolina. The gel-infused memory foamlayers 14, 16 may comprise a shape substantially similar to that of theinner foam core 12. In one embodiment, the gel-infused memory foamlayers 14, 16 each have a thickness (t) that is substantially equal toabout 1 inch, in order to provide comfort and resilience. If agel-infused memory foam layer is substantially thicker than about 1inch, the composite seat cushion 10 may exhibit poor rebound, such thatit may fail to resume its undeformed shape in a timely manner after auser stands up. Conversely, if a gel-infused memory foam layer comprisesa thickness (t) that is substantially less than about 1 inch, thecomposite seat cushion 10 may fail to provide the desired level ofcomfort. However, those skilled in the art of seat cushion manufacturingwill appreciate that thickness (t) may vary slightly, such as by typicalmanufacturing tolerances for such material. It will be appreciated thatin other embodiments, the gel-infused memory foam layers 14, 16 may havethicknesses (t) other than about 1 inch, for providing varying levels ofcomfort as may be desired.

In one embodiment, one or both of the gel-infused memory foam layers 14,16 may be adhered to the inner foam core 12 with glue to preventrelative movement between the gel-infused memory foam layers 14, 16 andthe inner foam core 12. It will be appreciated, however, that variousother methods of joining the gel-infused memory foam layers 14, 16 tothe inner foam core 12 may be used.

The composite seat cushion 10 may further include a first down prooftick layer 18 positioned on top of the first gel-infused memory foamlayer 14. In the embodiment shown, a second down proof tick layer 20 ispositioned below the second gel-infused memory foam layer 16. It shouldbe noted that other embodiments may not include a second down proof ticklayer 20. The down proof tick layers 18, 20 include a fill material. Inone embodiment, the fill material may comprise a blend of fiber materialwith one or more of duck feather and down. In the embodiment shown, thedown proof tick layers 18, 20 each include channels 22 for maintainingeven distribution of the fill material throughout the down proof ticklayers.

In another embodiment, a method of making a seat cushion 10 inaccordance with the principles of the present invention includespositioning at least one gel-infused memory foam layer 14 over at leasta portion of a top surface of a high-resiliency inner foam core 12, andpositioning a down proof tick layer 18 on top of the gel-infused memoryfoam layer 14. The method may also include adhering the at least onegel-infused memory foam layer 14 to the inner foam core 12. In anotherembodiment, the method may include adhering the down proof tick layer 18to the gel-infused memory foam layer 14. The method may further includepositioning the at least one gel-infused memory foam layer 14 over atleast a portion of a bottom surface of the inner foam core 12. Forexample, a single gel-infused memory foam layer may be wrapped aroundthe inner foam core 12, such that the gel-infused memory layer mayextend over a portion of the top surface and a portion of the bottomsurface. Alternatively, the method may include positioning a firstgel-infused memory foam layer 14 over at least a portion of the topsurface and positioning a second gel-infused memory layer 16 over atleast a portion of the bottom surface. The method may further includepositioning a second down proof tick layer 20 on the bottom of thesecond gel-infused memory foam layer 16. In one embodiment, the methodmay include encasing the seat cushion 10 within a cushion casing havinga side panel defined by a width dimension that is substantially equal toa thickness of the inner foam core 12.

While the present invention has been illustrated by the description ofone or more embodiments thereof, and while the embodiments have beendescribed in considerable detail, they are not intended to restrict orin any way limit the scope of the appended claims to such detail.Additional advantages and modifications will readily appear to thoseskilled in the art. The invention in its broader aspects is thereforenot limited to the specific details, representative apparatus and methodand illustrative examples shown and described. Accordingly, departuresmay be made from such details without departing from the scope or spiritof the general inventive concept.

What is claimed is:
 1. A composite seat cushion for use with an articleof furniture, the seat cushion comprising: a high-resiliency inner foamcore having a top surface, a bottom surface, and at least one sidesurface; at least one gel-infused memory foam layer extending over atleast a portion of the top surface; and a first down proof tick layerpositioned on top of the at least one gel-infused memory foam layer. 2.The composite seat cushion of claim 1, wherein the at least onegel-infused memory foam layer has a thickness of about 1 inch.
 3. Thecomposite seat cushion of claim 1, wherein the first down proof ticklayer includes a fill material comprising a blend of fiber material withat least one of duck feather or down.
 4. The composite seat cushion ofclaim 3, wherein the first down proof tick layer comprises a pluralityof channels for maintaining even distribution of the fill material. 5.The composite seat cushion of claim 1, wherein at least one of thegel-infused memory foam layer is adhered to the inner foam core, or thefirst down proof tick layer is adhered to the gel-infused memory foamlayer.
 6. The composite seat cushion of claim 5, wherein the at leastone gel-infused memory foam layer is adhered to the top surface of theinner foam core by glue.
 7. The composite seat cushion of claim 5,wherein the first down proof tick layer is adhered to the top of the atleast one gel-infused memory foam layer by glue.
 8. The composite seatcushion of claim 1, wherein the at least one gel-infused memory foamlayer further extends over at least a portion of the bottom surface. 9.The composite seat cushion of claim 1, wherein the at least onegel-infused memory foam layer comprises a first gel-infused memory foamlayer extending over at least a portion of the top surface and a secondgel-infused memory foam layer extending over at least a portion of thebottom surface, and further comprising a second down proof tick layerpositioned on the bottom of the second gel-infused memory foam layer.10. The composite seat cushion of claim 1, further comprising a cushioncasing for encasing the seat cushion, wherein the cushion casingincludes a side panel having a width dimension and a length dimension.11. The composite seat cushion of claim 10, wherein the thickness of theinner foam core is substantially equal to the width dimension of theside panel of the cushion casing.
 12. A method of constructing acomposite seat cushion, comprising: providing a high-resiliency innerfoam core having a top surface, a bottom surface, and at least one sidesurface; positioning at least one gel-infused memory foam layer over atleast a portion of the top surface; and positioning a first down prooftick layer on top of the at least one gel-infused memory foam layer. 13.The method of claim 12, further comprising adhering at least one of thegel-infused memory foam layer to the inner foam core or the first downproof tick layer to the gel-infused memory foam layer.
 14. The method ofclaim 12, further comprising positioning the at least one gel-infusedmemory foam layer over at least a portion of the bottom surface.
 15. Themethod of claim 12, wherein the step of positioning at least onegel-infused memory foam layer includes positioning a first gel-infusedmemory foam layer over at least a portion of the top surface andpositioning a second gel-infused memory layer over at least a portion ofthe bottom surface, and further comprising positioning a second downproof tick layer on the bottom of the second gel-infused memory foamlayer.
 16. The method of claim 12, further comprising encasing the seatcushion within a cushion casing having a side panel defined by a widthdimension that is substantially equal to a thickness of the inner foamcore.